OWNER’S MANUAL & OPERATING INSTRUCTIONS 4000 Starting Watts / 3500 Rated Watts Recoil Start PORTABLE GENERATOR MODEL NUMBER 46596 SAVE THESE INSTRUCTIONS Important Safety Instructions are included in this manual. MADE IN CHINA REV 46596-20120801 10006 Santa Fe Springs Road Santa Fe Springs CA 90670 USA / 1-877-338-0999 www.championpowerequipment.
Have questions or need assistance? Do not return this product to the store! WE ARE HERE TO HELP! Visit our website: www.championpowerequipment.com for more info: • Product Info & Updates • Frequently Asked Questions • Tech Bulletins • Product Registration – or – Call our Customer Care Team Toll-Free at: 1-877-338-0999 WARNING: The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
46596 4000 Starting Watts / 3500 Rated Watts Recoil Start PORTABLE GENERATOR Table of Contents Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Portable Power Generator. . . . . . . . . . . . . . . . . . 1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 This Booklet. . . . . . . . . . . .
ENGLISH 46596 Introduction Introduction Accessories Congratulations on your purchase of a Champion Power Equipment generator. CPE designs and builds generators to strict specifications. With proper use and maintenance, this generator will bring years of satisfying service. Champion Power Equipment manufactures and sells accessories designed to help you get the most from your purchase. To find out more about our covers, power cables and storm kits, please visit our web site at: www.
46596 ENGLISH Manual Conventions This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment. Follow all safety messages to avoid or reduce the risk of serious injury or death. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
ENGLISH 46596 Safety Rules WARNING Read this manual thoroughly before operating your generator. Failure to follow instructions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects, or other reproductive harm. DANGER Generator exhaust contains carbon monoxide, a colorless, odorless, poison gas. Breathing carbon monoxide will cause nausea, dizziness, fainting or death.
46596 ENGLISH DANGER Safety Rules WARNING Fuel and fuel vapors are highly flammable and extremely explosive. Fire or explosion can cause severe burns or death. Unintentional startup can result in entanglement, traumatic amputation or laceration. Rapid retraction of the starter cord will pull hand and arm towards the engine faster than you can let go. Unintentional startup can result in entanglement, traumatic amputation or laceration. Broken bones, fractures, bruises or sprains could result.
ENGLISH 46596 Controls and Features Read this owner’s manual before operating your generator. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Generator 1 7 2 3 6 4 5 5 (1) Fuel Tank – 3.8 gal. (14.4 L) capacity fuel tank. (5) Recoil Starter – Used to manually start the engine. (2) Choke – Used to start the engine. (6) Oil Filler Cap – Check and fill engine oil level.
46596 ENGLISH Controls and Features Power Panel 1 (1) 2 3 Engine Switch – Used to start or stop the generator. (2) Circuit Breakers – Protects the generator against electrical overloads. (3) Voltmeter – Used to display generator output voltage. (4) 120 Volt AC, 30 Amp Twist-Lock Receptacle (NEMA L5-30R) – May be used to supply electrical power for the operation of 120 Volt AC, 30 Amp, single phase 60 Hz electrical loads.
Controls and Features Parts Included Your 46596 Gasoline Powered Generator ships with the following parts: Spark Arrester Kit –– Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . 1 –– Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 –– Screw with Lock Washer. . . . . . . . . . . . . . . . . . . . 2 Other –– Oil Funnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 –– Spark Plug Socket.
46596 ENGLISH Your generator requires some assembly. This unit ships from our factory without oil. It must be properly serviced with fuel and oil before operation. If you have any questions regarding the assembly of your generator, call our help line at 1-877-338-0999. Please have your serial number and model number available. Remove the Generator from the Shipping Carton 1. Set the shipping carton on a solid, flat surface. 2. Remove everything from the carton except the generator. 3.
ENGLISH 46596 Assembly Add Fuel 1. Use clean, fresh, regular unleaded fuel with a minimum octane rating of 85 and an ethanol content of less than 10% by volume. 2. DO NOT mix oil with fuel. 3. Clean the area around the fuel cap. 4. Remove the fuel cap. 5. Slowly add fuel to the tank. DO NOT overfill. Allow approximately ¼ inch of space for fuel expansion. 6. Screw on the fuel cap and wipe away any spilled fuel. CAUTION Use regular unleaded gasoline with a minimum octane rating of 85.
46596 ENGLISH Generator Location Please consult your local authority. In some areas, generators must be registered with the local utility. Generators used at construction sites may be subject to additional rules and regulations. This generator must have at least five feet of clearance from combustible material. Leave at least three feet of clearance on all sides of the generator to allow for adequate cooling, maintenance and servicing. Place the generator in a well-ventilated area.
ENGLISH 46596 Operation Connecting Electrical Loads Do Not Overload Generator 1. Let the engine stabilize and warm up for a few minutes after starting 2. Plug in and turn on the desired 120 Volt AC single phase, 60 Hz electrical loads. –– DO NOT connect 3-phase loads to the generator. –– DO NOT connect 50 Hz loads to the generator. –– DO NOT overload the generator. Capacity NOTE Connecting a generator to your electric utility company’s power lines or to another power source may be against the law.
46596 ENGLISH Operation Operation at High Altitude The density of air at high altitude is lower than at sea level. Engine power is reduced as the air mass and airfuel ratio decrease. Engine power and generator output will be reduced approximately 3½% for every 1000 feet of elevation above sea level. This is a natural trend and cannot be changed by adjusting the engine. At high altitudes increased exhaust emissions can also result due to the increased enrichment of the air fuel ratio.
ENGLISH 46596 MAINTENANCE ANd STORAGE The owner/operator is responsible for all periodic maintenance . WARNING Never operate a damaged or defective generator . WARNING Oil Cont’d. NOTE Once oil has been added, a visual check should show oil about 1-2 threads from running out of the fill hole . If using the dipstick to check oil level, DO NOT screw in the dipstick while checking . Tampering with the factory set governor will void your warranty . WARNING Improper maintenance will void your warranty .
46596 ENGLISH Spark Arrester 1. Allow the engine to cool completely before servicing the spark arrester. 2. Remove the two screws holding the cover plate which retains the end of the spark arrester to the muffler. 3. Remove the spark arrester screen. 4. Carefully remove the carbon deposits from the spark arrester screen with a wire brush. 5. Replace the spark arrester if it is damaged. 6. Position the spark arrester in the muffler and attach with the two screws.
ENGLISH 46596 Maintenance and Storage Generator Maintenance Make certain that the generator is kept clean and stored properly. Only operate the unit on a flat, level surface in a clean, dry operating environment. DO NOT expose the unit to extreme conditions, excessive dust, dirt, moisture or corrosive vapors. CAUTION DO NOT use a garden hose to clean the generator. Water can enter the generator through the cooling slots and damage the generator windings.
46596 ENGLISH Specifications Spark Plugs Engine Specifications –– –– –– –– Model. . . . . . . Displacement. . Type . . . . . . . . Start Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66534 . . . . . 196cc 4-Stroke OHV . . . . .
17 REV 46596-20120801 70 75 69 61 88 62 87 86 85 71 73 72 76 77 60 66 68 67 74 65 28 59 12 89 13 63 64 78 83 79 84 90 28 58 80 81 82 1 2 3 4 5 40 6 7 36 42 41 39 45 8 9 10 11 56 55 38 37 35 34 44 43 57 12 13 54 14 15 16 46 18 32 31 30 29 17 28 33 50 49 48 47 16 53 52 51 25 16 19 20 21 24 26 28 27 22 23 Specifications ENGLISH 46596 Parts Diagram
46596 ENGLISH # 1 2 Part Number 168FD-2-GC ST02FD-02100011 Parts List Description Engine Plug-B Qty # Part Number Description 1 47 ST02FD-04100010 Mount Vibration, Fuel Tank Qty 4 1 48 ST02FD-04100014 Washer Φ6 4 GB93 6 Lock Washer Φ6 4 3 ST02FD-02100012 Plug-A 1 49 4 504.191100.05 Rotor Assembly 1 50 GB5789 M6×20 Flange Bolt M6×20 4 5 ST02FD-02100005 Flange Bolt M8×233 1 51 ST168F-1070006A Fuel Filter 1 6 GB96 8 Washer φ8 1 52 168.070100.
19 REV 46596-20120801 98 95 1 3 2 5 4 7 6 8 9 11 12 13 14 10 16 15 9 17 19 43 44 18 26 21,22 47 46 41 42 45 40 39 24 9 23 48 27 25 49 28 30 29 31 26 33 66 65 9 83 34 68 35 24 36 67 37 70 1 80 19 71 79 82 78 1 77 85 84 87 86 90 89 88 91 93 92 94 32 96 95 56 57 58 50 59 60 61 62 63 64 53 54 55 52 51 72 38 69 73 74 75 76 81 97 20 Specifications ENGLISH 46596 Engine Parts Diagram
46596 ENGLISH # 1 2 Part Number GB5789--86-FB6-8 ST160F--1061200 Description Flange bolt 6*8 Recoil starter knob Qty # Part Number Description 5 58 ST168F--1130002-CPE gasket,insulator(no asbestos) Qty 1 1 59 ST160F--1010001 Stud bolt 6*110 2 ST168F-2-1010100-G Cylinder head 1 3 ST160F--1061100-Q Recoil starter comp 1 60 4 ST160F--1061005 Recoil starter spring 1 61 ST168F-2-1030009-G gasket,cylinder head 1 5 ST160F--1061009 Recoil starter rope 1 62 ST168F--1040002 v
Specifications Wiring Diagram 21 REV 46596-20120801 ENGLISH 46596
46596 ENGLISH Troubleshooting Problem Cause Solution Generator will not start No fuel Add fuel Faulty spark plug Replace spark plug Unit loaded during start up Remove load from unit Generator will not start; Low oil level Fill crankcase to the proper level Generator starts but runs roughly Choke in the wrong position. Adjust choke. Spark plug wire loose Attach wire to spark plug Out of fuel Fill fuel tank Low oil level Fill crankcase to the proper level.
ENGLISH 46596 Warranty WARRANTY CHAMPION POWER EQUIPMENT 2 YEAR LIMITED WARRANTY Warranty Qualifications Champion Power Equipment (CPE) will register this warranty upon receipt of your Warranty Registration Card and a copy of your sales receipt from one of CPE’s retail locations as proof of purchase. Please submit your warranty registration and your proof of purchase within ten (10) days of the date of purchase.
Champion Power Equipment, Inc. (CPE), and the United States Environment Protection Agency (U.S. EPA.) Emission Control System Warranty Your Champion Power Equipment (CPE) engine complies with the U.S. EPA emission regulations. YOUR WARRANTY RIGHTS AND OBLIGATIONS: The US EPA AND CPE are pleased to explain the Federal Emission Control Systems Warranty on your 2012 small off-road engine and engine powered equipment.
EMISSION CONTROL SYSTEM WARRANTY The following are specific provisions relative to your Emission Control System Warranty Coverage. 1. APPLICABILITY: This warranty shall apply to 1997 and later model year small off-road engines. The ECS Warranty Period shall begin on the date the new engine or equipment is delivered to its original, end-use purchaser, and shall continue for 24 consecutive months thereafter. 2.
EMISSION-RELATED PARTS INCLUDE THE FOLLOWING: (using those portions of the list applicable to the engine) Systems covered by this warranty Fuel Metering System Fuel regulator, Carburetor and internal parts Air Induction System Air cleaner, Intake manifold Ignition System Spark plug and parts, Magneto ignition system Exhaust System Exhaust manifold, catalytic converter Miscellaneous Parts Tubing, Fittings, Seals, Gaskets, and Clamps associated with these listed systems.
